Linear motor transport for packaging and other uses

ABSTRACT

The invention provides in some aspects a transport system comprising a guideway having a plurality of regions in which one or more vehicles are propelled, where each such vehicle includes a magnet. Disposed along each region are a plurality of propulsion coils, each comprising one or more turns that are disposed about a common axis, such that the respective common axes of the plurality of coils in that region are (i) substantially aligned with one another, and (ii) orthogonal to a direction in which the vehicles are to be propelled in that region. The plurality of coils of at least one such region are disposed on opposing sides of the magnets of vehicles being propelled along that region so as to exert a propulsive force of substance on those magnets. In at least one other region, the plurality of coils disposed on only a single side of the magnets of vehicles being propelled in that region exert a propulsive force of substance thereon—regardless of whether the plurality of coils in that region are disposed on a single or multiple (e.g., opposing sides) of those magnets.

REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Patent Application Ser. No.61/880,910, filed Sep. 21, 2013, entitled “LINEAR MOTOR TRANSPORT FORPACKAGING AND OTHER USES.”

This application is related to U.S. patent application Ser. No.13/623,124, filed Sep. 20, 2012, entitled “Transport System Powered byShort Block Linear Synchronous Motors and Switching Mechanism,” and theancestors thereof, including U.S. patent application Ser. No.12/692,441, filed Jan. 22, 2010, entitled “Improved Transport SystemPowered By Short Block Linear Synchronous Motors,” U.S. patentapplication Ser. No. 12/359,022, filed Jan. 23, 2009, entitled“Transport System Powered by Short Block Linear Synchronous Motors,”U.S. Provisional Patent Application bearing Ser. No. 61/184,570, filedJun. 5, 2009, entitled “Improved Transport System Powered By Short BlockLinear Synchronous Motors.” The teachings of the foregoing applicationsare hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention pertains to transport systems and more particularly, interalia, to linear synchronous motor guideway-based transport systems. Theinvention has application, by way of non-limiting example, in packaging,assembly, production line, laboratory, printing, and other applications.

There are many types of transport systems that can move objects on aguideway. Examples include: wheel-suspended vehicles propelled by rotaryor linear motors, maglev or air-cushion suspended vehicles propelled bylinear motors or cables, vehicles that move in tubes propelled by airpressure, vehicles supported or guided by bearings, and vehicles thatare moved on conveyor belts.

Existing transport systems have many useful applications but there areopportunities for substantial improvement, for example, in the precisemovement of relatively small and closely spaced objects on a complexguideway.

Small and medium size objects are often transported on conveyor beltsbecause this eliminates the need for wheels or other mechanisms tosuspend, guide and propel the objects. Belt transport systems arerelatively inexpensive but they lack precise control that is oftenneeded and they require substantial maintenance because of many movingparts. Other approaches to low-cost transport include air propelledvehicles moving in tubes and the use of gravitational forces to moveobjects down an incline, but these approaches have even less precisecontrol.

The advantages of using linear synchronous motor (LSM) propulsion arewell known and described, by way of non-limiting example, in U.S. Pat.Nos. 7,458,454, 7,448,327, 6,983,701, 6,917,136, 6,781,524, 6,578,495,6,499,701, 6,101,952, and 6,011,508, all assigned to the assignee hereofand the teachings of all of which are incorporated herein by reference.

Still, the applicant seeks to further improve transport systems,apparatus and methods that are based on LSMs. One object of theinvention is to do just that.

Another related object of the invention is to provide such systems,apparatus and methods as are useful in packaging, assembly, production,laboratory, printing, and other applications.

A further related object of the invention is to provide such systems,apparatus and methods as are adapted for use with fast-moving and/orclosely-spaced vehicles.

A still further related object of the invention is to provide suchsystems, apparatus and methods as can be easily assembled, reassembled,and reconfigured.

A yet still further related object of the invention is to provide suchsystems, apparatus and methods to facilitate complex packaging, assemblyand other operations.

Yet a still further related object of invention is to provide suchsystems, apparatus and methods to provide for improved switching ofvehicles and payloads that they carry.

Still yet a further related object of the invention is to provide suchsystems, apparatus and methods as provide for improved multi-levelaccess to vehicles and payloads that they carry.

Still another object of the invention is to provide such systems,apparatus and methods which maximize throughput, yet, minimize“footprint.”

SUMMARY OF THE INVENTION

The foregoing are among the objects attained by the invention, whichprovides in some aspects a transport system comprising a guideway havinga plurality of regions in which one or more vehicles are propelled,where each such vehicle includes a magnet. Disposed along each regionare a plurality of propulsion coils, each comprising one or more turnsthat are disposed about a common axis, such that the respective commonaxes of the plurality of coils in that region are (i) substantiallyaligned with one another, and (ii) orthogonal to a direction in whichthe vehicles are to be propelled in that region.

In related aspects, the invention provides a transport system, forexample, as described above, in which the plurality of coils aredisposed on only one side of the vehicles in at least one region of theguideway. An example of this might include individual branches of amerge/diverge region (alternatively referred to herein as a “diverge”region, or the like), where geometries and/or working requirementsafford the opportunity of and/or necessitate such coil utilization alongeach individual branch of the diverge.

Still other related aspects of the invention provide transport systems,e.g., as described above, in which the vehicle magnets are disposed ononly one side of their respective vehicles—e.g., the same side as thaton which the coils are disposed.

In other related aspects of the invention, the coils are disposed onboth, opposing sides of the vehicles in one or more such regions. Anexample of this might include a straight-away or inclined region, wheregeometries/requirements of the guideway afford theopportunity/necessitate such a configuration.

In other aspects of the invention, there is provided a transport systemof the type described above in which, although coils are disposed onopposing sides of the vehicles propelled in that region, only the coilson one of those sides are “working” coils. This can be, for example,because only the coils on one side are activated or, for example,because only the coils on one side are close enough to the magnets ofthe vehicles to exert a propulsive force of substance thereon (e.g., apropulsive force that contributes measurably, if not also significantly,to movement of the vehicles along the guideway).

According to related aspects of the invention, the common axes of theplurality of coils in a region are aligned radially (e.g., as on acurved section of the guideway).

According to still other related aspects of the invention, at least oneof the regions includes a back iron disposed adjacent to the pluralityof coils, e.g., to focus the magnetic field on magnets of the vehiclesbeing propelled therethrough.

According to still other aspects of the invention, the guideway isdisposed to propel vehicles along one or more planes, including any of ahorizontal plane (e.g., a tabletop configuration) and a vertical plane(e.g., an over-under configuration), and at multiple levels (e.g., floorheight, bench height and/or overhead height).

According to yet other aspects of the invention, a guideway as describedabove includes a merge/diverge section (alternatively referred to hereinas a “diverge” section, or the like) that includes a flipper, movingrails and/or other switching mechanism to facilitate redirection of avehicle passing thereon.

According to yet other aspects of the invention, a guideway as describedabove includes one or more rails, guide surfaces or other means on whichthe vehicles travel. In related aspects, the vehicles include wheels,bearings or other means that cooperate with the rails and/orcorresponding surfaces of the guideway.

Further aspects of the invention provide a transport system, e.g., asdescribed above, where at least one of the regions is a merge/diverge(alternatively referred to herein as a “diverge,” or the like) that anyof (i) directs a vehicle from an upstream portion of the guideway to anyof two or more branches in a downstream portion, and/or (ii) directs avehicle from any of two or more branches in the downstream portion ofthe diverge to a common upstream portion of the diverge.

This can be, for example, any of a left-right, up-down or other divergein a plane of motion defined by the diverge region. The diverge regionmay include a plurality of working coils that are disposed on only oneside of the vehicles in the upstream portion and that apply lateral andpropulsive forces effecting vehicle motion toward a selected one of thebranches. The diverge region may also include a plurality of workingcoils on both, opposing sides of the vehicles in at least a downstreamportion of the selected branch so as to facilitate propelling them, oncethey have been diverted to that branch.

Still other aspects of the invention provide vehicles and otherapparatus for use on guideways as described above. Such vehicles caninclude, for example, magnet or magnet arrays that are centrallydisposed on (or in) the vehicle body and that magnetically couplepropulsion coils in the guideway. The vehicles can, further, engagerunning surfaces of the guideway on portions of the vehicle body distalwith respect to those magnet or magnet arrays. According to relatedaspects of the invention, such engagement can be direct (e.g.,body-to-running surface contact) and/or via wheels, bearings, slides,etc.

Still yet further aspects of the invention provide methods of operationof guideway systems, guideways and vehicles, e.g., as described above.

The foregoing and other aspects of the invention are evident in thedrawings and in the text that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention may be attained byreference to the drawings, in which:

FIG. 1 depicts a guideway system according to one practice of theinvention;

FIG. 2 depicts a portion of a guideway system according to a furtherpractice of the invention;

FIG. 3A depicts a vehicle of the type used in practice of the invention;

FIGS. 3B-3C are cut-away views of varying embodiments of a straight-awaymodule of the type shown in the guideway system of FIG. 2;

FIG. 4 is a cutaway, exploded view of the guideway system shown in FIG.2;

FIG. 5 depicts a merge/diverge module (alternatively referred to hereinas a “diverge” module, or the like) of a guideway system according tothe invention;

FIGS. 6A and 6B are perspective views of vehicles of the type used inpractice of the invention;

FIGS. 7 and 8 are perspective views of still other vehicles of the typeused in practice of the invention; and

FIGS. 9A-9D are perspective, see-through views of wheel mounts used invehicles according to some practices of the invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

Overview

FIG. 1 depicts a linear synchronous motor (LSM) guideway 10 fortransporting vehicles according to one practice of the invention. Theguideway 10 includes a plurality of modules, each delineated in part bydashed lines in the drawing. Exemplary ones of the modules are labelledas elements 12 a, 12 b, 12 c, . . . 12 t, respectively, although morethan that number of modules are shown. Other embodiments may contain agreater or fewer number of modules configured in the manner of theillustrated guideway 10 or otherwise. Indeed, in some embodiments, anentire guideway may be embodied in a single module.

The modules 12 a-12 t, which typically each include at least one runningsurface for a vehicle 24 (FIG. 2), and, in some instances, multiple suchsurfaces, are coupled with one another to form a pathway suitable forpropelling vehicles 24. Those running surfaces and, more generally themodules, are arranged to form regions that include straightaways,curves, inclines, and so forth. Each such region can comprise a singlemodule or multiple modules, depending on implementation specifics.

Those regions, moreover, may define one or more planes of motion inwhich the vehicles 24 are propelled. This can include module(s) whoserunning surfaces define, by way of non-limiting example, a verticalplane of motion as exemplified by modules 12 a-12L, the running surfacesof which define a path on vertically disposed plane 14. This can alsoinclude, by way of further non-limiting example, a horizontal plane ofmotion as exemplified by modules 12 m-12 q, the running surfaces ofwhich define a path on horizontally disposed plane 16. Modules 12 r-12 tdefine another such horizontal plane of motion—though, vehicles 24disposed on a path defined by them move transversely vis-à-vis thosemoving on the path defined by modules 12 m-12 q. Other planes of motionalong which vehicles 24 traveling on guideway system 10 may be propelledare evident upon study of FIG. 1. Still others may be formed in otherembodiments constructed in accord with the teachings hereof.

The modules 12 a-12 t may, moreover, be configured for conveyingvehicles 24 traveling on system 10 at different heights or levels. Thiscan include, by way of non-limiting example, conveying vehicles 24 attabletop height as exemplified by modules 12 m-12 o, and modules 12 c,12 e, 12 g, and 12 i, among others, the running surfaces of which definepaths of motion for vehicles 24 traveling thereon at a tabletop heightvis-à-vis an operator 18. This can also include, by way of furthernon-limiting example, conveying the vehicles 24 at overhead heights asexemplified by modules 12 r-12 t, the running surfaces of which definepaths of motion for vehicles 24 traveling thereon at an overhead heightvis-à-vis operator 18. As will be appreciated from FIG. 1, the modulesof guideway 10 can convey vehicles 24 at other heights, such as forexample floor-height, instead and in addition.

FIG. 2 depicts a portion of an LSM guideway 20 similar to, but defininga different pathway than, guideway 10. As above, guideway 20 comprisesmodules whose running surfaces define regions in which vehicles 24 arepropelled along pathways in the same and/or different planes of motionand heights, and so forth. The illustrated modules of FIG. 2 are similarin construction and operation to modules 12 of guideway system 10 (ofFIG. 1), though, here (in FIG. 2) they are labeled differently, i.e., aselements 22 a-22 g, and they are arranged in a different configurationand, thereby, define a different pathway. To that end, it will beappreciated that one or more of the modules 22 a-22 g of the portion 20of FIG. 2 can be substituted into the guideway system 10 of FIG. 1 andvice versa.

As shown in FIG. 2, a guideway according to the invention can include,by way of example, modules 22 a-22 c that define straight-away paths,e.g., of varying lengths (here, 250 mm, 500 mm and 1000 mm, by way ofnon-limiting example), for vehicle motion.

Such a guideway can also include modules for use in defining curvedpaths of motion, e.g., as shown here with module 22 d defining a curvedpath in a horizontal plane of motion, as well as modules 22 e, 22 f foruse in regions defining curved paths in vertical planes of motion. Thedegree of curvature of modules 22 d-22 f may vary depending on thespecifics of implementation. Thus, for example, both 90-degree and180-degree curves are shown in the drawing; other embodiments mayutilizes modules with other degrees of curvature, instead or inaddition. It will also be appreciated that the radii of the curves neednot be the same for all (curved) regions and that the radius of a curvemay even change within a given region.

The modules of a guideway according to the invention can also includemerge/diverge modules, for example, of the type labelled as 22 g in thedrawing. These can be left-right merge/diverge modules that directvehicles in a horizontal plane of motion, up-down merge/diverge modulesthat direct vehicles in vertical planes of motion, and so forth,depending on the pathway options defined by a particular guideway. And,although some guideways according to the invention can includemerge/diverge modules that direct vehicles in a single, common plane ofmotion (e.g., horizontal or vertical or so forth), other guidewaysaccording to the invention include merge/diverge modules that directvehicles in multiple respective planes of motion—e.g., one or moremodules for horizontal planes of motion, one or more modules forvertical planes of motion, and so forth).

The foregoing and other modules are shown in FIG. 1, e.g., inclinedcurve module 12 u. It will be appreciated, of course, that thestraight-away, curve, merge-diverge and other modules shown in FIGS. 1-2are merely examples and that other embodiments may utilize modulesincorporating different shapes.

Vehicles

Vehicles 24 of the illustrated embodiment may be constructed in themanner of LSM vehicles known in the art—as adapted in accord with theteachings hereof—and, more particularly, for example, in the manner ofthe vehicles described and shown in International ApplicationPublication No. WO2014047104 and U.S. Patent Publication 2013/0074724,the teachings of both of which are incorporated by reference herein,including by way of non-limiting example, in the manner of the vehiclesdisclosed in FIGS. 2-5, 15-17, 23A through 26B of thosepublications—again, as adapted in accord with the teachings hereof.

FIGS. 3A and 6-8 depict the central bodies (or frames) of vehicles 24according to practices of the invention. Like reference numbers in thosedrawings identify like components of the frames and vehicles andguideway systems in which they are incorporated. As will be evident inthose drawings and in the discussion that follows, those vehiclesgenerally (a) include magnet or magnet arrays that are centrallydisposed on (or in) the vehicle body and that magnetically couplepropulsion coils in the guideway modules, and (b) engage runningsurfaces of the guideway on portions of the vehicle body distal withrespect to those magnet or magnet arrays. Such engagement can be direct(e.g., body-to-running surface contact) and/or via wheels, bearings,slides, etc.

More particularly, by way of example, FIG. 3A depicts the frame ofvehicle 24 according to one practice of the invention and of the typesuitable for use with guideways 10, 20. That frame is a generally rigidstructure having the cross-section of an I-beam or H-beam (or, in someinstances, a T-beam). Thus, the frame has a generally planar centralportion 24 c or “web” (using the terminology associated with I- andH-beams) of generally rectangular cross-section, the distal ends ofwhich web terminate in distal end portions 24 a, 24 b or “flanges”(again, using beam terminology) that, too, can be of generallyrectangular cross-section or otherwise, as shown. Like the serifs of theletters “I” or “H” whose cross-sections the frame approximates, theflanges at ends 24 a, 24 b can be centered on their respective ends ofthe web 24 c and at right angles to it, though other embodiments mayvary in these regards (e.g., off-centered flanges, angled flanges orotherwise).

FIGS. 6-8 illustrate, also by way of example, frames utilized in avehicle 24 according to other practices of the invention. Thosealternate frames are generally planar, but they lack flanges of the typedescribed above at both of the end portions 24 a, 24 b (although, theembodiment of FIG. 6A includes an “inverted” flange—here, shaped like anarrowhead—at distal end 24 b). A generally rectangular cross-section isnot a requirement of frames of vehicles used with guideways 10, 20, asevidenced by way of example by the frame shown in FIG. 8, which has anenlarged cross-section at end 24 a, e.g., for added stability dependingon payload requirements, guideway configuration and/or vehicle velocityprofiles on that guideway.

Although in some embodiments, the vehicle 24 slides directly on runningsurfaces of the modules 12 a, et seq., and 22 a, et seq., in theillustrated embodiments, it includes wheels, bearings, skids or othercomponentry to facilitate movement of the vehicle along the guidewaydefined by the running surfaces of those modules (here, wheels 24 ddemarked by dashed lines in FIG. 3A and in solid lines in the otherdrawings). Those wheels, bearings, skids, or other movement-facilitatingcomponentry (hereinafter, collectively, “wheels,” for sake ofconvenience and without loss of generality) may extend from the flangesat ends 24 a, 24 b, e.g., as illustrated in FIG. 3A, or otherwise.Though the examples discussed below and shown in the drawing are wheels,per se, it will be appreciated that the teachings are equally applicableto bearings, skids, or other movement-facilitating componentry of thevehicle 24.

Thus, for example, the wheels may extend from an inverted flange, e.g.,as shown in FIG. 6A, or directly from the web 24 c or other portion(s)of the frame, vehicle 24 or mounting mechanisms associated therewith. Byway of example are wheels mounted on pivoting members 24 f in the recess24 g of the vehicle frame, e.g., as shown in FIGS. 6A, 6B; wheel(s)mounted on sliding member 24 h in such recess, e.g., as shown in FIG. 7;and, wheels mounted directly on planar portion of frame, e.g., as shownin FIGS. 6B, 7 and 8.

Referring to FIGS. 6-8, mounting mechanisms such as, for example,illustrated pivots 24 f and slides 24 h can be employed to facilitatemounting/dismounting the vehicle 24 to/from guideway 10, 20, tofacilitate loading/unloading of the vehicle, to facilitate vehiclemotion over the guideway, or otherwise. Further details of thosemechanisms are illustrated in FIG. 9.

Referring to FIGS. 9A, 9B, for example, there are shown, respectively,front and perspective see-through views of sliding member 24 h, whichincludes a body portion (to which the wheel 24 d is mounted) and pinportions extending therefrom which are slidingly disposed in channels 24j of the frame, as shown. Likewise, referring to FIGS. 9C, 9D, forexample, there are shown, respectively, front and perspectivesee-through views of pivoting member 24 f, which includes a body portion(to which the wheel 24 d is mounted) that pivots about an axle or pin 24k, as shown. The sliding member 24 h and pivoting member 24 f can bebiased, via a spring or otherwise, to appropriately suspend (orotherwise position) the vehicle 24 in its respective loaded, unloaded,and other modes, on the guideway.

Wheels 24 d may be arranged on the vehicle frames in a variety of ways.For example, one or more wheels may extend from each frame insymmetrical fashion. Or, by way of further example, referring to FIG.3A, a pair of wheels may be centered on and extend from one flange(e.g., at end portion 24 a), while only a single wheel extends from theother flange (at end portion 24 b). (Only one side of the vehicle 24frame is shown in that drawing; a similar arrangement of wheels may beprovided on the other side.) FIGS. 6-8 shows still other arrangements ofwheels, all by way of example. Specifics of the arrangement utilized forany given embodiment are a function of vehicle load type, load“footprint,” and load balance, vehicle velocity profile, and so forth.

Wheels 24 d may extend normally (i.e., at substantially a 90° angle)from the surface of the flange, frame or component of vehicle 24 towhich they are mounted. Conversely, they may extend at an angle fromthat surface, e.g., as shown in FIGS. 3A-3C and 6A, all by way ofexample. Still further, such wheels may have a cupped surface (e.g., asshown in FIGS. 3A-3C), flat surface (e.g., as shown in FIG. 6A) orchamfered surface (e.g., as shown in FIGS. 6B and 7-9).

As examples of slides or bearings that may be used to facilitate vehiclemovement are pins 24 m shown in FIGS. 6A, 6B. These can be utilized, forexample, where vehicle-to-guideway contact is less regular, e.g., duringloading/unloading, vehicle movement over guideway transitions, etc., orotherwise.

Referring to FIGS. 6-8, the frame of illustrated vehicle 24 extends(here, by a length L) along an axis x running parallel to the runningsurfaces (or pathway) defined by module 22. Taking into account the spanof wheels, bearings, skids or other componentry discussed above, the endportions 24 a, 24 b of the vehicle 24 have a width w along an axis y(transverse to the x axis) that approximates the width w′ of theguideway defined by the running surfaces 28 a, 28 b of module 22,thereby, allowing the frame to be supported and/or its motion to beconstrained/guided by those surfaces 28 a, 28 b, though otherembodiments may vary in this regard.

In typical embodiments, magnets 24 e are disposed on each side of web 24c, though, in some embodiments, they may be disposed on only oneside—e.g., the side on which the working propulsion coils 26 aredisposed (as discussed below in connection with FIGS. 3B and 3C). Themagnets may be of the type and configuration commonly used in LSMapplications. Thus, for example, the magnets on each side of the web 24c may be configured in an array, e.g., such as a Halbach array or, forexample, an array with one middle magnet that has a South pole facingaway from the web and two half magnets on the ends that have a Northpole facing in that same direction, though a single magnet or otherconfigurations of multiple magnets may be employed. The magnets maycomprise NdFeB in order to achieve high fields, but they can use othermaterials, such as ceramic, when cost or external fields must be low orSamarium Cobalt when the operating temperature is high. In embodimentswhere there is risk of adverse interaction between magnets on adjacentvehicles 24, a ferromagnetic piece can be placed around the perimeter ofthe magnet(s) (array) to minimize magnetic fields from adjacent vehiclesfrom interfering with each other. Though, for sake of simplicity andwithout loss of generality, the magnets 24 e of the illustratedembodiment are shown as being distinct from the web 24 c on which theyare disposed, it will be appreciated that the magnets 24 e may beintegral to the web 24 c, e.g., as shown in FIGS. 6-8.

In some embodiments, vehicles 24 may constitute little more than aframe, magnet and, optionally, wheels, bearings, or skids, etc. In thoseembodiments, payloads (not shown) can be placed on, affixed to orotherwise coupled to those frames (and/or to the magnet or othercomponents). In other embodiments, the vehicles 24 may include housings,jigs or other apparatus (not shown) that are attached to one or both ofthe flanges 24 a, 24 b or other components, e.g., in order to facilitatecarrying of such payloads.

Modules

The guideways 10, 20 may be constructed in the manner of LSM guidewaysknown in the art—as adapted in accord with the teachings hereof—and,preferably, for example, in the manner of the guideway described andshown in International Application Publication No. WO2014047104 and U.S.Patent Publication 2013/0074724, the teachings of both of which areincorporated by reference herein—again, as adapted in accord with theteachings hereof. Particular reference is had in this regard, by way ofexample, to the sections of the aforesaid incorporated-by-referenceapplications entitled “Guideway,” “Low friction sliding surface,”“Magnet array,” and “Linear propulsion motor,” as well as to the figuresreferred to in those sections, all by way of example. The guideways 10,20 may be of unitary construction, though, preferably, they arefabricated from modules, for example, of the type described in theaforesaid incorporated-by-reference applications in the sectionsentitled “Guideway modules” and in the figures referred to in thatsection—again, as adapted in accord with the teachings hereof.

More particularly, the construction of the modules of guideways 10, 20of the illustrated embodiment is depicted in FIGS. 3B-3C. The former(FIG. 3B) is a cut-away view of a module having propulsion coils 26disposed on only one side of magnets of vehicles 24 propelled in theregion defined by that module; the latter (FIG. 3C), both sides.Although straight-away module 22 a is provided here as the example, itwill be appreciated that the other modules of the guideways according tothe invention may be similarly constructed, though, their respectiveshapes and the pathways that they define may vary.

Referring to FIG. 3B, the module 22 a, like the other modules ofguideways 10, 20, can have several components: running surfaces 28 a-28b, propulsion coils 26 comprising an LSM motor and, optionally (buttypically) position sensing logic, power electronic components, and/ormicroprocessors that serve as controllers for the module or for “blocks”defined within and/or by one or more modules. All of these componentscan be contained in a common housing (e.g., element 40 of FIG. 4) orotherwise assembled together on-site, at the factory, or otherwise, inthe conventional manner known in the art, (e.g., as described in U.S.Pat. No. 6,578,495, entitled “Modular Linear Motor Tracks And Methods ofFabricating Same,” assigned to the assignee hereof, the teachings ofwhich are incorporated herein by reference, as adapted in accord withthe teachings hereof.

Illustrated module 22 a has multiple running surfaces on which vehicles24 are propelled. Those surfaces can serve, for example, to carry theweights of those vehicles and/or to guide them as they pass along themodule.

In the illustrated embodiment, the running surfaces 28 a, 28 b aredefined by opposing rail pairs 29 a, 29 b, as shown, and, moreparticularly, in this drawing, by right-side rail pair 29 a andleft-side rail pair 29 b, that are spaced-apart by a gap Δ. That gap Δis sufficient to permit at least web 24 c (and, as necessary, magnetarray 24 e and other structures on web 24 c) to pass between the rails29 a, 29 b, while the end portions 24 a, 24 b of vehicle 24 and/orwheels, slides, bearing or other structures thereon move on those rails.Of course, it will be appreciated that the designations “right” and“left,” here, are a function of the orientation of the module 22 a inthe illustration, and that in other embodiments that incorporate suchopposing rail pairs, they may comprise a top-side pair and a bottom-sidepair or some other orientation of opposing rail pairs.

Illustrated rail pairs 29 a, 29 b each comprise two rails of generallyround (here, circular) cross-section along which pass wheels or othercomponentry of the vehicles that facilitate such movement (as notedabove). Of course one or both of the two rails (of each respective pair29 a, 29 b) can be of other shapes and, more specifically, for example,of different cross-sections, both from each other and/or from that shownin the drawing. Thus, for example, one or both rails of each pair can begrooved (e.g., to accommodate bearings on the vehicles in lieu of thewheels shown here), flat (e.g., to accommodate skids), and so forth—allby way of example.

And, although each running surface of illustrated module 22 a is definedby an opposing pair of rails, in other embodiments, it may comprise agreater or fewer number of rails or other structures. For example, eachrunning surface may be defined by only a single rail. Indeed a runningsurface need not comprise any or only rails: it can comprise one or morelow friction sliding surfaces (e.g., of the type disclosed inincorporated-by-reference International Application Publication No.WO2014047104 and U.S. Patent Publication 2013/0074724, for example, inthe section entitled “Low-Friction Sliding Surface” and the accompanyingdrawings, as adapted in accord with the teachings hereof), grooves, andso forth, all as adapted in accord with the teachings hereof. Forexample, in some embodiments, a module includes one or more runningsurfaces, each defined by such a low friction sliding surface, albeitone that includes a slot which runs along that surface in the directionof motion of the vehicles and which accommodates the web 24 c of eachrespective vehicle just as opposing rails of the pairs of rails 29 a, 29b accommodate that web 24 c.

Modules, e.g., 22 a, having an arrangement of running surfaces andpropulsion coils 26, e.g., as shown here (with respect to astraight-away) and discussed elsewhere herein, can (also) beadvantageous, among other places, in diverge regions of the type shown,for example, in FIG. 5, where geometries and velocity constraints maydictate that and/or afford the opportunity to (a) dispose working coilson only one side of the upstream portion of each branch of a divergeregion, yet, (b) dispose working coils on both sides of the downstreamportions of both branches—all as shown, by way of nonlimiting example,in the diverge module of FIG. 5.

Propulsion coils 26 are of a type conventionally used in LSMs, asadapted in accord with the teachings hereof, each comprising one or moreturns that are disposed about a common axis (that is, an axis common tothe turns of that respective coil). In the illustrated embodiment, thecoils 26 are “working coils,” that is, coils that are disposed closeenough to the vehicle magnets 24 e and powerful enough when activated toexert a propulsive force of substance thereon (as opposed to, forexample, merely a lateral or steering force) in order to propel thevehicles 24 along the guideway, here, in the direction of the x axis. Inorder to focus their magnetic fields, the propulsion coils 26 caninclude back irons 26 b of the type known in the art and, additionally,each can include a core (not shown).

In diverge regions, e.g., of the type shown in FIG. 5, working coils 26in the upstream portion of each branch of the diverge can be disposed insufficient proximity of the vehicle magnets 26 such that, when the coilson a single side of the vehicle 24 are activated, those coils exertsufficient force to propel the vehicle into and through the divergebranch while, optionally serving (instead or in addition to flippers,moving rails and/or other switching mechanisms) to diverting the vehicle24 toward a specific one of the branches.

Although discussed above and elsewhere herein are configurations inwhich propulsion coils are disposed on only one side of the guideway inone or more regions thereof, it will be appreciated in some embodiments,coils may be placed on both sides but activated (i.e., “working,” asdefined above), on only one side in one or more such regions.

Comparing FIGS. 3B and 3C, in the former (FIG. 3B) working propulsioncoils 26 are disposed on only one side of the guideway and, moreparticularly, on one side of module 22 a and, still more particularly,on one side of the web 24 c and magnets 24 e of vehicles 24 propelled onthat module 22 a; while, in FIG. 3C, working propulsion coils 26 aredisposed on both sides of the guideway and, more particularly, bothsides of module 22 a and, still more particularly, on both sides of theweb 24 c and magnets 24 e of vehicles 24 propelled on that module 22 a.A guideway can comprise modules with working propulsion coils on oneside, on both sides, or a combination thereof, as shown in FIG. 4.Indeed, a given module may have working coils 26 on one side over partof the guideway pathway it defines and on two sides on the rest of thatpathway.

Inclusion of working propulsion coils on one side or both sides of theguideway can be necessitated by geometries and/or working requirementsof the guideway. This is by way of example, only, since other factors,e.g., such as cost, availability, assembly constraints, etc., candetermine where and whether there is the opportunity or necessity forcoils on one side, the other side or both.

For example, working coils can be disposed on both, opposing sides of anincline or other region where vehicle loads necessitate that greatercumulative propulsive forces be exerted on the vehicles in order topropel them along the guideway with suitable acceleration (ordeceleration); or, conversely, that working coils only need by disposedon one side in straight-away regions where unloaded vehicles need bepropelled with little or no acceleration/deceleration.

Likewise, geometries and velocity constraints may dictate that and/orafford the opportunity to (a) dispose working coils on only one side ofthe upstream portion of each branch of a diverge region, yet, (b)dispose working coils on both sides of the downstream portions of one orboth branches—all as shown, by way of nonlimiting example, in thediverge module of FIG. 5. By placing or activating coils on only oneside of the upstream portion of each branch, lateral forces applied bythose (working) coils can—in lieu or along with lateral forces exertedby a flipper or other switching mechanism—direct a vehicle 24 movingthrough that portion to a selected one of the branches and, when thevehicle 24 enters that branch, it can be (more forcefully) propelled bycoils on both sides.

In modules 12 a, et seq., and 22 a, et seq.—and, more generally, regionsof a guideway 10, 20—in which coils 26 are disposed on opposing sides ofthe magnets of the vehicles 24, both sets of coils can be working (asdefined above) at the same time, though, they need not be. This can be,for example, because only the coils on one side are “working” coils or,for example, in the case of a diverge region of the guideway, becauseonly the coils on one side are close enough to the magnets of thevehicles to exert a propulsive force of substance thereon.

Referring back to FIGS. 3B-3C, the portion of each running surface,e.g., 28 a, 28 b, within each straightaway, curve, or other regiondefined by the module 22 a defines a plane p that includes the x-axis(i.e., the axis defining the direction in which the vehicle 24 ispropelled in that region) or a parallel axis thereto, and is orthogonalto a plane m defined by and/or parallel to the plane of web 24 c and onwhich the magnet 24 e lies, as illustrated. When activated, each coil 26generates an axially-directed magnetic field, as indicated in thedrawing by the arrows marked 26 m. However, unlike the prior art, inwhich coils of an LSM guideway are oriented so that their respectiveaxially-directed magnetic fields 26 m are normal to the plane p definedby the running surfaces, in the illustrated embodiment, the coils 26 areoriented so that their axially-directed fields 26 m fall in planes thatare parallel to the plane p (while still being normal to the plane m).In addition, in the illustrated embodiment, the respective common axesof the plurality of coils 26 in each region (i.e., each straightaway,curve, etc.) defined by the module 22 a (or in which the module forms apart) are substantially aligned with one another. In straight-awayregions, “aligned” means linearly aligned or, expressed another way, insuch regions, the fields 26 m are normal to the direction of motion inwhich vehicles are propelled in those regions. Whereas, in curvedregions, “aligned” means radially aligned and, too, in such regions, thefields 26 m are normal to the direction of motion in which vehicles arepropelled in those regions.

This is further illustrated in FIG. 5, which shows a left-right divergemodule 22 g and its constituent coils 26 and running surfaces 28 a(further running surfaces 28 b, if any, incorporated into the module arenot shown). As indicated by lines 28 m on the drawing:

-   -   the respective common axes 22 m-a of the plurality of coils 26        in the straight-ahead region 22 g-a of the merge/diverge module        are substantially aligned with one another and normal to the        axis of motion x-a of vehicles (not shown) in that region;    -   the respective common axes 22 m-b of the plurality of coils 26        in the curve region 22 g-b of the merge/diverge module are        substantially aligned with one another, albeit radially, and        normal to the curved “axis” of motion x-b of vehicles (not        shown) in that region.

Although FIG. 5 illustrates a left-right merge/diverge module thatdirects a vehicle 24 in a horizontal plane of motion, the teachingshereof are equally applicable to up-down merge/diverge modules invertical planes of motion and/or other corresponding modules fordirecting vehicles in other respective planes of motion, and so forth.And, as noted above, although some guideways according to the inventioncan include merge/diverge modules that direct vehicles in a single,common plane of motion (e.g., horizontal or vertical or so forth), otherguideways according to the invention include merge/diverge modules thatdirect vehicles in multiple respective planes of motion—e.g., one ormore modules for horizontal planes of motion, one or more modules forvertical planes of motion, and so forth).

In addition to the foregoing, the diverge module 22 g can include aflipper, moving rails and/or other switching mechanism to facilitateredirection of a vehicle passing thereon. In this regard, reference ishad to the switching mechanisms disclosed in incorporated-by-referenceInternational Application Publication No. WO2014047104 and U.S. PatentPublication 2013/0074724 including, by way of non-limiting example, inFIGS. 20A-20B, 22A-22B, 24A-24B, and the accompanying text, of thosepublications—all as adapted in accord with the teachings hereof.

The diverge module 22 g can, moreover, be constructed and operated inthe manner of a diverge section of the type disclosed in thoseincorporated-by-reference applications including, by way of non-limitingexample, in the 18, FIGS. 20A through 26B and the accompanying text ofthose publications—again, as adapted in accord with the teachingshereof.

Described herein are systems and methods meeting the objects set forthabove. It will be appreciated that the embodiments shown in the drawingsand discussed in the accompanying text are merely examples of theinvention and that other embodiments, incorporating modifications tothat shown here, fall within the scope of the invention. Thus, by way ofexample, whereas some regions, sections, modules and/or the like of theguideway discussed above and shown in the drawings are occasionallyreferred to as “diverge” regions, sections, modules, and/or the like,respectively, such references are shorthands for and refer to(throughout this specification and the attached claims) what are morecommonly known as “merge/diverge” regions, sections, modules, and/or thelike respectively. And, by way of further example, whereas curve,merge/diverge, straightaway and/or other regions, sections, modulesand/or the like are referred to herein as lying in horizontal orvertical planes of motion, it will be appreciated that they may lie inplanes of motion having other orientations instead or in addition.

In view of the foregoing, what we claim is: 1.-37. (canceled)
 38. Atransport system comprising: a linear synchronous motor guideway in oron which one or more vehicles are propelled, where each such vehicleincludes magnets; wherein the guideway comprises one or more modules,each module comprising a plurality of propulsion coils, and wherein eachof the propulsion coils in a region of the guideway comprises turns thatare disposed about a common axis, such that the respective common axesof the plurality of propulsion coils in the region are substantiallyaligned with one another, and orthogonal to a direction in which thevehicles are to be propelled in the region; and wherein the plurality ofpropulsion coils of the region are disposed on two opposing sides of andin laterally facing relation to the magnets of the vehicles propelled onthe region, and the propulsion coils exert a propulsive force ofsubstance on the magnets of the vehicles.
 39. The system of claim 38,wherein the modules include any of straight sections, curved sections,and inclined sections.
 40. The system of claim 38, wherein the region iscurved and the respective common axes of the plurality of propulsioncoils in the region are radially aligned with one another.
 41. Thesystem of claim 38, wherein the region is straight and the respectivecommon axes of the plurality of propulsion coils in the region arelinearly aligned with one another.
 42. The system of claim 38, whereinthe guideway is arranged to propel vehicles along one or moredirections, including a horizontal direction and a non-horizontaldirection.
 43. The system of claim 42, wherein the non-horizontaldirection comprises a vertical direction.
 44. The system of claim 43,wherein the guideway is arranged to propel the vehicles at two or moreheights.
 45. The system of claim 44, wherein the two or more heightsinclude a floor height, a tabletop height, and an overhead height. 46.The system of claim 38, comprising another region in which a secondplurality of propulsion coils are disposed on a single side of and inlaterally facing relation to magnets of the vehicles, and the secondplurality of propulsion coils exert a propulsive force of substance onthe magnets of the vehicles.
 47. The system of claim 38, wherein thevehicles have a generally I-shaped cross section.
 48. The system ofclaim 38, wherein the vehicles are generally planar.
 49. The system ofclaim 38, wherein the vehicles have magnets on two mutually oppositesides.
 50. A transport system comprising: a linear motor guideway havinga region in which a vehicle is propelled, the region including aplurality of propulsion coils, and the vehicle including magnets, eachof the propulsion coils in the region of the guideway comprising aplurality of turns that are disposed about a common axis, the respectivecommon axes of the plurality of propulsion coils in the region beingsubstantially aligned with one another, and orthogonal to a direction inwhich the vehicle is to be propelled; wherein the plurality ofpropulsion coils of the region are disposed on two opposing sides of andin laterally facing relation to the magnets of the vehicles propelled onthe region, and the propulsion coils exert a propulsive force ofsubstance on the magnets of the vehicles.
 51. The system of claim 50,wherein the vehicles have a generally I-shaped cross section.
 52. Thesystem of claim 50, wherein the vehicles are generally planar.
 53. Thesystem of claim 50, wherein the vehicles have magnets on two mutuallyopposite sides.
 55. A transport system comprising: a linear motorguideway having a plurality of propulsion coils for propelling a vehicleincluding magnets, each of the propulsion coils comprising a pluralityof turns that are disposed about a common axis, the respective commonaxes of the plurality of propulsion coils being substantially alignedwith one another, and orthogonal to a direction in which the vehicle isto be propelled; wherein the plurality of coils are disposed on twoopposing sides of and in laterally facing relation to the magnets of thevehicle, and the propulsion coils exert a propulsive force of substanceon the magnets of the vehicle.
 56. The system of claim 55, wherein thevehicles have a generally I-shaped cross section.
 57. The system ofclaim 55, wherein the vehicles have magnets on two mutually oppositesides.